Bump cap hat

ABSTRACT

The presented invention is a light weight protective bump cap hat. The bump cap hat has an insert comprised of flexible joints and wings that allow for adjustable horizontal and vertical dimensions of the insert to more readily accommodate various head shapes and sizes. The bump cap insert also has venting channels to allow better venting around the comfort pad and out the crown of the bump cap while being worn by a user.

CLAIM OF BENEFIT TO PRIOR APPLICATIONS

This application claims the benefit of U.S. Provisional Application No. 62/748,474 filed Oct. 21, 2018; and is a continuation of application Ser. No. 16/659,164 filed Oct. 21, 2019. Such applications are fully incorporated by reference herein.

FIELD

The present invention relates generally to protective headwear. More particularly, the present invention relates to a bump cap hat that is lighter, more flexible, better ventilated and more comfortable than the prior art.

BACKGROUND

Bump cap are useful for protecting the wearer's head from bumps, cuts and bruises as a result of contact with objects such as overhead pipes, low ceilings and other objects. Bump cap can be configured to be inserted into a cap or hat, or can be integrated into a cap.

Bump caps that are currently integrated into hats have two issues in warmer environments: heat retention and weight.

There is an unfulfilled need for a bump cap hat that is better ventilated, lighter, and more flexible to comfortably accommodate a variety of head sizes.

SUMMARY

The disclosed bump cap hat provides head protection that is lighter, better ventilated, more flexible for comfort and fit, and cooler for use in hotter temperatures, and designed for ease of use while wearing head phones and ear protection.

This summary is not intended to limit the scope of the invention, or describe each embodiment, implementation, feature or advantage of the invention.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is perspective side view of a preferred embodiment of a bump cap hat with integrated bump cap insert showing venting apertures.

FIG. 2 is a rear view a preferred embodiment of a bump cap hat with integrated bump cap insert showing venting apertures.

FIG. 3 is a front perspective view of a preferred embodiment of a preferred embodiment of a bump cap hat showing venting apertures.

FIG. 4 is a bottom plan view of the bump cap showing the moisture-wicking liner, and foam impact layer, and various air channels and venting apertures of the bump cap insert FIG. 5 is a top plan view of the moisture wicking liner removed from the bump cap insert.

FIG. 6 is a perspective left side view of the bump cap insert showing the wings, flex joints and the plurality of venting apertures.

FIG. 7 is a top plan view of the bump cap insert showing the venting channels and apertures on the crown portion.

FIG. 8 is a bottom plan view of the bump cap insert showing the moisture wicking liner and the air channels that run above the comfort pad.

FIG. 9 is a front elevation view of the bump cap insert showing the front visor portion and the two adjacent flex joints.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

A bump cap hat with integrated bump cap insert is herein described. The bump cap hat disclosed herein is comfortable, highly-ventilated, and comprises an impact-resistant inner shell that provides protection against cranial bumps, bruises, scrapes, and other minor head injuries. The bump cap hat insert disclosed herein provides head protection that meets the EN 812-2012 standard and weighs less than 5 oz/135 g.

The exemplary bump cap hat is a ball styled hat that includes ventilation in the form of apertures on the crown and side panel portions of the hat. The bump cap hat is configured to accept a bump cap insert. The bump cap insert is made of a light-weight high-density polyethylene and weighs less than 130 g. The bump cap insert comprises air channels in the crown portion of the shell to allow for air flow and venting. The interior of the insert comprises a moisture wicking liner with raised portion to create area for air flow, and a layer of expanded polypropylene foam (EPP) for impact and bump protection. The air channels are vented by channel vent holes. The preferred embodiment bump cap disclosed herein also comprises at least four rear fins. A pair of lower rear fins and a pair of upper rear fins are preferred. The rear fins are defined by joints that allow the fins to flex vertically and horizontally. This flexibility creates a more universal fit by allowing the bump cap to flex in both vertical and horizontal directions to allow for the adjustment for fit over a variety of head shapes and sizes. This flexibility also aides in relieving pressure on the neck during the turning or other movement of the head of a user.

The lower side perimeter of the bump cap insert comprises two scooped-out portions adjacent the ears of the user. The scoop allows for the use of hearing production, head phones and the like. The flex of the lower fins further aides in allowing the scooped-out portion to flex to accommodate the use of various sized headphones and hearing protection.

The front visor of the bump cap insert is more rounded and slopes more gradually from top to bottom than the prior art. This feature better accommodates and better supports the forehead portion of bump cap hat disclosed herein.

The bump cap hat will now be described with reference to the figures.

Bump cap hat 10 is a ball type cap that has been adapted for use with bump cap insert 100. More particularly, bump cap hat 10 comprises areas that are perforated with vent apertures. These areas are right crown vent panel 20, left crown vent panel 22, right side panel 25 and left side panel 30. This vent panels cooperate with bump cap insert 100 to vent warm air out and away for the user's head. Though the panels herein are defined by seams, one skilled in the art would understand that the seams could be placed in different locations and the spirit of the invention is met so long as the areas vented remains generally as described herein. Bump cap hat 10 also comprises rear panel 12, forehead panel 13, sweatband 14 and visor 35.

Bump cap insert 100 comprises a crown portion 110, a rear visor 115, a front visor portion 120, lower wings 130 and upper wings 140. The flex joints depicted are lower flex joints 145 and upper flex joints 147. Lower flex joints 145 and lower perimeter 150 define lower wings 130. Lower flex joint 145 provides for much of the horizontal and vertical flexibility of lower wings 130. Upper flex joints 147 and rear visor 115 define upper wings 140. Upper flex joints 147 provide much of the horizontal and vertical flexibility of upper wings 140. Lower perimeter 150 defines scoop areas 152 on either side of bump cap insert 100 which allows for a user of bump cap insert 100 to more easily wear ear production, head phones, ear muffs and the like. Flex joints 145 and 147 cooperate, along with the generally overall flexibility of bump cap 100, to allow scooped areas 152 to deform sufficiently to accommodate various sizes of objects worn over a user's ears.

As best can be viewed in FIGS. 4, 7 and 8, air channels 155 run above moisture wicking liner 179. Moisture wicking liner 179 comprises raised portions 180. Moisture wicking liner 179 is constructed to wick moisture away from the head of a user to promote additional cooling. Raised portions 180 provide area for air venting through crown 110 via air channel vent holes 160 while bump cap 100 is in use. Foam impact layer 187 is located between moisture wicking liner 179 and crown 110. Impact layer 187 helps to absorb shock imparted on bump cap hat 10. Crown 110 comprises air channels 155. Air channels 155 contain air channel vent holes 160. Bump cap 100 comprise a plurality of surface apertures 170 located throughout the bump cap's surface. These surface apertures 170 provide additional venting as well as reducing the weight of the bump cap.

As best depicted in FIGS. 4 and 5, front visor 120 is defined by front flex joints 185 and crown 110. The rounded shape of front visor 120 in combination with flex joints 185 allows front visor to move in and out to allow better fit under bump cap hat 10.

Bump cap insert 100 is configured to be secured into bump cap hat 10 by placing lower perimeter 150 of bump cap insert 110 into the flap formed by sweatband 14.

The use of a ball type cap in the disclosure above is exemplary. It should be clear to one skilled in the art that ball cap insert 110 may be used with other hats.

While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiments, it will be apparent to those of ordinary skill in the art that the invention is not to be limited to the disclosed embodiments. It will be readily apparent to those of ordinary skill in the art that many modifications and equivalent arrangements can be made thereof without departing from the spirit and scope of the present disclosure, such scope to be accorded the broadest interpretation of the appended claims so as to encompass all equivalent structures and products. Moreover, features or aspects of various example embodiments may be mixed and matched (even if such combination is not explicitly described herein) without departing from the scope of the invention.

For purposes of interpreting the claims for the present invention, it is expressly intended that the provisions of Section 112, sixth paragraph of 35 U.S.C. are not to be invoked unless the specific terms “means for” or “step for” are recited in a claim. 

What is claimed is:
 1. A light weight bump cap insert comprising: a bump cap insert shaped to conform to a top portion of a human skull, having a crown, the crown having a top side and an under side, a rear visor, and a front visor; the bump cap insert comprising at least two wings, each wing having at least one adjacent flex joint, wherein each flex joint allows for horizontal and vertical movement of each wing; the crown top side having at least two channels that protrude from the crown top side, the at least two channels defining a plurality of apertures such that air flow is allowed to flow from the crown underside into the channels and out through the apertures; the crown under side comprising a moisture wicking insert; and, wherein air flow from the crown underside into the channels and out though the apertures is not fully obstructed by the moisture wicking insert.
 2. The bump cap insert of claim 1 wherein the bump cap insert front visor is rounded to better accommodate a forehead portion of a hat into which the bump cap insert is inserted.
 3. The bump cap insert of claim 1 wherein the bump cap insert also comprises a lower perimeter, the lower perimeter defining at least one scooped out portion adjacent an ear of a user, wherein the scooped out portion serves to accommodate hearing protection, head phones and the like, worn by a user. 